Building panels for and coupling joints therebetween in prefabricated buildings



DOUGLAS BUILDING PANELS FOR AND COUPLING JOINTS THEREBETWEEN IN PREFABRICATED BUILDINGS Filed Dec. 16, 1959 March 26, 1963 4 Sheets-Sheet l Pie. 2

M r 1963 D. D. DOUGLAS 3,082,489

BUILDING PANELS FOR AND COUPLING JOINTS THEREBETWEEN IN PREFABRICATED BUILDINGS Filed Dec. 16, 1959 4 Sheets-Sheet 2 March 26, 1963 DOUGLAS 3,082,489

BUILDING PANELS FOR AND COUPLING JOINTS THEREBETWEEN IN PREFABRICATED BUILDINGS Filed D60. 16, 1959 4 Sheets-Sheet 5 FIG. 8

March 26, 1963 3,082,489

D. D. DOUGLAS BUILDING PANELS FOR AND COUPLING JOINTS THEREBETWEEN IN PREFABRICATED BUILDINGS 16, 1959 Filed Dec. 4 Sheets-Sheet 4 Fl (7. H

United States Patent 3,082,489 BUILDING PANELS FOR AND COUPLING JUINTS THEREBETWEEN IN PREFABRICATED BUILD- INGS David D. Douglas, Huntington, N.Y. (Black Hall Road, Epsom, N.H.) Filed Dec. 16, 1959, Ser. No. 859,916 12 Claims. (Cl. 20-8) The present invention relates to building panels which may be put to advantageous service in a variety of types of buildings as floor, roof and the like subassembly units thereof, and coupling joints for effectively connecting them together.

An object of the present invention is to provide such panel units in a form which are readily constructed and assembled in mass production procedure and which allow simple coupling thereof by labor of little skill and with the use of a few simple tools while permitting ready demountation for rearrangement and economical and rapid construction of additions.

Another object of the invention is to provide such panels in modular units of unique structural form and simple coupling thereof in joints on one or more sides of any one unit to adjacent companion panel units which when coupled together effectively may accommodate shear and bending moment stresses of heavy vertically imposed loads without requiring beams and supports intermediate edge or marginal supports, a plurality of the modular units being securely coupled together in spans by simple but effective joints which properly transfer the forces of vertical loads to terminal or marginal span supports or Widely spaced supports while efficiently carrying the bending moment stresses.

A further object of the invention is to provide such a modular panel unit and a coupling joint structure thereof which features top and bottom skin zone means with the top ones of a plurality of panel units so associated together in end-supported spans or edge-supported assembled areas as to assure eflfective lateral transfer of compressive forces and with the bottom ones of the coupled panel units so connected together as to transfer effectively in lateral directions the bending moment stresses in tension.

An additional object of the invention is to provide such a modular panel unit with a modified coupling joint structure which permits assembly in spans of cantilever type wherein forces in tension may be effectively transferred laterally through one or more such joint structures at the top skin zone means or layers and forces in compression may be effectively transferred laterally through the same joint structures at the bottom skin zone means or layers.

Still other objects of the invention are to provide such modular panel unit-s and their joint coupling means in forms permitting their ready employment in a variety of types of unusually sturdy and durable buildings without dictating the sizes or shapes of the latter and which will permit such buildings to be rapidly and securely assembled in economical manner with meticulous compliance with restrictions and as best adapted to the existing sites, and while allowing complete satisfaction of the demands of the intended occupants and those imposed by regional climatic conditions; embodiments being readily varied to satisfy esthetic requirements as to materials, texture, finish and the like; and expansion and alteration of buildings erected therewith being readily permitted without destructive loss of units of the present invention which had al ready been installed.

Yet another object of the invention is to provide structural embodiments that may be readily mass produced and assembled by economical manufacturing procedures FIG. 1 is a perspective view of a partially assembled floor area constructed from a plurality of modular panel units each embodying one form of the present invention and coupled together by an exemplary form of joint thereof, illustrating support only of outside edges of the assembled area;

FIG. 2 is an enlarged perspective view of one of the panel units depicted in FIG. 1;

FIG. .3 is a further enlarged elevational edge view,

with parts broken away and in section, of a corner of the panel unit shown in FIG. 2, as viewed from the of line 3-3 of the latter;

FIG. 4 is an exploded elevational edge view of a pair of companion panel units of the type shown in FIGS. 1 to 3 incl., with parts broken away, showing the parts of one form of the coupling joint which may be employed to advantage to connect them together;

FIG. 5 is an enlarged elevational section, with parts broken away, of adjacent portions of a companion pair of the panel units of FIGS. 1 to 4 incl. as juxtaposed in a coupling joint employing the elements illustrated in FIG. 4;

FIG. 6 is a side elevational view of a span of assembled plurality of the panel units of FIGS. 1 to 5" incl. coupled together by the joint structure illustrated in FIG. 5, showing support of the ends of the span and illustrating the distribution of stresses due to imposed vertical load;

FIG. 7 is a horizontal section taken substantially on line 77 of FIG. 2, illustrating the internal structural details of the panel unit shown therein;

FIG. 8 is a plan view of one of the pair of couplingjoint straps shown in FIGS. 4 and 5;

FIG. 9 is a vertical section to reduced scale, with parts broken away, of a side edge of a modified form of the panel unit of the present invention;

FIG. 10 is a side elevational view, with parts broken away and in section, of adjacent portions of a companion pair of modified panel units of the present invention, illustrating another embodiment of the joint coupling structure characterized by different means in the form of a channeled key employed to tie together the bottom skin zone means or layers;

FIG. 11 is a sectional detail taken substantially on line 11-41 of FIG. 10, with parts broken away and in section, showing the tying key in top plan view and partially sectioned;

FIG. 12 is a view similar to FIG. 6, with parts broken away, of a span consisting of a plurality of panel units coupled together with modified joint structure permitting ends of the span to cantilever in bearing distributed imposed vertical load with the supports being widely spaced but located inward of the span terminal ends beneath joint structures coupling together companion pairs of the panel units; and

FIG. 13 is a view similar to FIG. 5, showing the joint, structure of FIG. 12 at a support and illustrating the distribution of load forces between companion panels through such joint structure which bears upon a support.

position Referring to the drawings, in which like numerals identify similar parts throughout, it will be seen that an embodiment of the panel unit of the present invention, illustrated in FIGS. 1 to 8 incl. and referenced 10 therein, comprises a straight-sided flat structure having verticallyspaced top and bottom planar. skin zone means 11 and 12' and intervening core means 13. Each of the panel units 10 preferably isrectangular or square having four like side edges 1414 so as to constitute a modular floor, roof and likesubassembly unit which may be paired on all-four sides with companion like panel units and connectedthereto by like coupling joints so that a plurality thereofmay-beassembled together to define an assembly area or a structurally continuous slab. It is intended that only marginal edges of such an assembly slab be supported on foundation walls or edge beams, such as those illustrated at 15, 15 in FIGS. =1 and 6-. It will be understood from'the description here following that no intervening supporting beams, such as stringers, reaching across from opposite edge beams need be or are intended to be employed beneath the panel units or joints between comp-anion pairs thereof inwardly of the edge supports.

As will be-best'understood from FIGS. 1 to 5 incl. and 7, the embodiment of the panel unit here illustrated by'wayof example consists of a planar top skin zone means 11 in the form of alayer which may be made from a sheet of plywood, hardboard or other suitable sheet material. The planar bottom skin zone means 12 may likewisebe in the form of a layer of similar sheet material. Theplanar top and bottom skin layers 11 and 12 are vertically spaced and rectangular core means 13 is mounted therebetween. The rectangular core means 13 has four vertical outside edges 1616 interposed between the top and bottom skin layers 11 and 12 with edge zones 1717. and 18-18 of the latter respectively extending laterally outward beyond the core vertical outside edges intoverhanging relation to define paired top and bottom lateral edge flanges on all four sides.

As willbebmt understood in FIGS. 3, 5 and'7, each vertical outside edge 16 of the core means 13 includes a vertical strip 19, which may also be a sheet of plywood, hardboard or the like. The four outside edge strips 1919 of the core means 13 together define a rectangular frame or box which may constitute all of the core means, if desired, and this rectangular frame and the associated top and bottom layers 11 and 12 together enclose a chamber 20; Proper mounting of the edge strips 19--19 relative to the bottom layer 12 with assurance of right angular disposition thereof is assured by employing a plurality of tnansversely-extending blocks 2121, vertical corner blocks 2222 and intervening vertical blocks 23-43, with the parts all suitably fastened or glued together. It will be noted from FIGS. 3, 4 and 5 that the bottom edges of the sidestrips 1-9-'19 terminate short of the inward faces of the bottom edge flanges 1818 so as to provide notches 2424 for a purpose to be explained later. Such horizontal blocks 2121 and vertical blocks 2222 and 2323 appreciably strengthen the core means 13 so as to assure that it will effectively carry resultant shearing forces. Forces of applied vertical load travel horizontally to the supports so that resultant shearing forces are at angles and these forces are carried almost entirely by the intermediate core means.

' The core means 13 may also include a central vertical blockor' post 25 with intermediate vertical strips 26-26 subdividing the chamber 20- into quarters and bridged across between the central post and the intermediate posts 23-23, as is-illustrated in FIG. 7. Additional horizontal blocks 2727 may, if desired, be employed in conjunction with the intermediate partition or bridge strips 2626 to anchor the latter securely in right angular relation to the bottom layer 12 with these parts also securely fastened or glued together. The bridge structure comprising intermediate quartering block's 27-27 and intermediate partition or bridge strips 2626 together resist deflection of the top skin layer 11 relative to the bottom skin layer 12 under centrally applied load. Preferably the core means 13 also includes filler material, such as bodies of rock wool 28, to fill the remaining voids in the chamber 20 and to provide good insulating qualities.

As will be explained later, various other types of core means arranged between the top and bottom skin zone means may be employed to advantage for particular services. It will also be understood that the top and bottom skin layers 11 and 12 of panel units of the present invention, similar to those illustrated at 10, and other sheet elements thereof, may, if desired, be made of material other than wood or fiber products, such as sheet metal, e.g., aluminum or steel, suitable plastic sheeting and other equivalent sheet material, and there may be applied to surfaces thereof, which are exposed to view, wear or climatic conditions, either protective and/ or decorative coatings within the scope of the present invention.

Secure anchorage of the core means outside edge strips 19-19 to top skin layer 11 may be obtained by the employment of horizontally-extending elongated strips 29- 29, each of which is fixedly mounted in the angle between the vertical outside face of one of said core strips 19 and the top edge flange 17 which overhangs the latter, and with opposed faces thereof securely fastened together by suit-able fastening means, such as glue. Strips 29-29 constitute shear strips with each having a vertical outside face Bali-provided with a longitudinally-extending groove 31 for reception of shear spline means or a key. In a coupling joint between a companion pair of juxtaposed panelnnits 10, 10 the opposed grooves. 31, 31 in the opposed shear strips 29, 29 thereof may be V-shaped, as shown, and the interposed shear spline means may be in the form of an elongated strip 32 of rectangular or square section with one half of the shear strip securely. seating in one of the grooves and the other half thereof securely seating in the opposed groove 31 when these panel units are coupled together in the manner explained hereinafter.

The opposed edges 33, 33 of marginal flanges 17, 17 of the top skin layers 11, 11 in the juxtaposed panel'units 10, 10 are to be arranged in lateral stress transfer relation relative to each other. In many installations this relative relation of the marginal flanges 17, 17 of top skin layers 11, 11 will be for the purpose of transferring compressive stress therebetween and this may be accomplished either by an interposed member or by direct abutting relation; When, for this purpose, the opposed top layer flange edges 33, 33 are to be brought to abutting contact of each other in a disconnectable coupling joint, as in the embodiment illustrated in FIGS. 1 to 8 incl., the outside edge face 30 of each shear strip 29 will extend laterally outward no farther than the layer flange edge thereabove so as not to interfere with such desired abutting contact, as will be understood from FIG. 5. It will also be noted from FIGS. 3, 4, and 5 that each shear strip 29 is spaced appreciably above the top face 34 of the bottom edge flange 18 located therebelow so that opposed open-faced channels 35, 35 are defined, together providing a closed lateral channel chamber 135, which may be used to advantage when companion panel units 10-10 are coupled together.

In each coupling joint, which impermanently connects together juxtaposed outside edges 14, 14 of each companion pair of the panel. units 10, 10, the bottom skin layers 12, 12 are to be disconnectably connected together, in "accordance with the present invention, in a manner effectively to transfer therebetween bending moment stress in tension. The greatest bending moment stress occurs at the center of a span since this is at the greatest distance from the terminal end or outside edge supports. Thus, effective practice of the present invention requires direct connection together of the bottom skin layer edge flanges 18, 18 by tying means of a nature providing suitable strength for effective direct lateral transfer therebetween of lateral forces in tension. Coupling joint structure of the present invention assures effective attainment of this requirement in providing elongated connecting or tying means extending longitudinally along and adjacent to the opposed bottom skin zone means edges of the paired panel units with this elongated connecting means being connected to the opposed bottom skin zone means edges at at least a large number of closely spaced points which disconnectably tie them directly together for direct lateral transfer therebetween of the bending moment stress in tension.

In the embodiment illustrated in FIGS. 1 to 8 incl., such disconnectable tying means is illustrated by way oi example as including at least one elongated strap or batten, and preferably a pair thereof as are shown at 36 and 136, with each strap or batten juxtaposed to and lapping against either the top faces 34, 34 or the bottom faces 37, 37 of the substantially aligned bottom layer edge flanges 18, 18. Each of the bottom layer edge flanges 18 is provided with a longitudinally-extending series of transversely-spaced vertical holes 38-38 located relatively closely together. Each of the tying straps or battens 36 and 136 is provided with a pair of transversely-spaced, longitudinally-extending series of holes 39-33 and 139- 139 with those of one series aligned with the holes 38-38 in one of the edge flanges 18 and those of the other series aligned with the holes in the other opposed edge flange 18. As will be best understood from FIGS. 4 and 5, the aligned bottom edge flanges 18, 18 are then securely tied together by the elongated straps or battens 36 and 136 when suitable fastening elements are inserted in the aligned holes. For this purpose, the fastening elements which are inserted in the aligned holes preferably may be in the form of demountable tying pins, such as hollow drive pins 40-40, which may be of an OD. slightly greater than the ID. of the aligned holes for tight frictional fit therein and, if desired, each such tying pin may be split longitudinally and formed of spring steel so as to have certain transverse resiliency facilitating drive to seated position While assuring secure anchorage in the aligned holes. As a result, the aligned bottom layer edge flanges 18, 18 are directly connected together in a strong butt joint for direct lateral transfer therebetween of bending moment stress in tension. It will be understood that such tying means or pins may be in the form of bolts and nuts, which when snugly pulled up will clamp the edge flanges 18, 18 between the opposed faces of the straps or battens 36 and 136 so as to assure frictional grip continuously and uninterruptedly along the full extent of the faces of the edge flanges aligned in the butt joint, but it has been found by tests that the proposed drive pins are efliciently effective in carrying the imposed loads While facilitating rapid assembly and disassembly procedures. The close spacing of the tying pins may be of the order, for example, of about one and one-half inches (1.5) center-to-center for modular panel units of the present invention, which may be about thirty-nine inches (39") along each side edge with the pins having an CD. of about one-half inch /2 It will be noted from FIGS. 4 and 5 that the side edges of the top butt joint tying strap 36 or batten seat within the notches 24, 24 provided in the side edges 14, 14 of the opposed pair of companion modular panel units 10, 10. This seating assures that when the drive pins 40-40 are driven up through the holes 39-39 and 139-139 of the bottom butt strap or batten 136 and the holes 38-38 of the edge flanges 18, 18 aligned therewith, advance of the top ends of the pins through the holes 39-39 and 139-139 in the top butt strap or batten 36 cannot lift the latter, thereby assuring that the drive pins will efiectively reach through all of the aligned holes.

It will thus be apparent, particularly by reference to FIGS. 4 and 5, that in order to assemble together juxtaposed side edges 14, 14 of a pair of companion modular panel units 10, 10 the opposed side edges of these companion panel units will be moved laterally toward each other in the direction of the arrow 41 in FIG. 4 with a spline strip 32 interposed between the opposed V-shaped grooves 31, 31 so as to securely seat therein when the companion panel units are brought together in edge abutting relation in the manner illustrated in FIG. 5. The top butt strap or batten 36 may, prior to bringing these panel side edges 14, 14 together, be seated upon one of the bottom edge flanges 18 with a side edge thereof seated in the notch 24 thereabove, as is illustrated in FIG. 4. Thus, the other side edge of this strap or batten 36 will then slide over the top face 34 of the other bottom edge flange 18 as the companion panel unit is moved laterally to juxtaposition, finally to seat in the other notch 24 temporarily to hold it securely against driving force applied to the tying pins 40-40. The bottom butt strap or batten 136 is then lapped to the bottom faces 37, 37 of the opposed and juxtaposed bottom edge flanges 18, 18 with alignment of its holes 39-39 and 139-139 with the holes 38-38 in the edge flanges. Then a plurality of the drive pins 40-40 are driven up through the aligned holes to complete the butt joint.

In order to disassemble one of the panel units 10 rapidly and simply from a companion panel unit 10 paired therewith, it is merely necessary to drive the drive pins 48-40 farther upwardly into the channel chamber 135, thereby freeing all of the elements of the butt joint. Since the butt joint structure is the only means provided for securely tying companion panels units of the FIGS. 1 to 8 incl. embodiment together in a coupling joint, this dismounting of the butt joint elements will then permit removal of one panel unit relative to the other, and if such panel unit has been tied to adjacent panel units in the construction of an assembly area or slab, as is proposed in FIG. 1, similar dismounting procedure is practiced for each coupling joint. As a result, alterations are readily permitted without any destructive damage to the panel units which had been previously assembled. The aligned closed channel chambers -135 which extend laterally in normal directions through an assembly area or slab made up from a plurality of the modular panel units 10-10 additionally permit ready concealed installation therethrough of plumbing lines and electrical supply cables. Since such rapid and simple dismounting of panel units relative to each other is a desirable feature of coupling joints of the present invention, the shear splines 32-32 preferably are and need not be fastened in the opposed spline strip grooves 31-31.

In FIGS. 5 and 6, transfer of load forces and opposing forces are illustrated by arrows. For example, in FIG. 6 arrows 42-42, indicate the direction of forces imposed upon a span of a plurality of the modular panel units 10-10 by imposed vertical load. Such vertical load force arrows 42-42 are also shown in FIG. 5. Since the greatest shear stress occurs at the supports, such as at 15, 15 in FIG. 6, because this is where the vertical forces all pile up, the maximum shear thereat is indicated by the arrows 43, 43 therein, which are opposed to and balanced out by opposing forces of the supports illustrated by the arrows 44, 44. Forces of shear, which is a tendency for one part under load to slide past an adjacent part, are illustrated by the arrows -45, 45 in the FIG. 5 coupling joint, and such relative shear motion is effectively resisted in the coupling joint chiefly by the shear strips 29, 29 and the intervening shear spline 32. In transferring the shear stress horizontally through a span to the terminal end or edge supports, such as 15, 15, the top skin layer of the span is required to transmit laterally forces in compression. This is effectively accomplished in accordance with the present invention by providing that the opposed top zone means edges in a coupling joint be arranged in lateral compressive stress transfer relation relative to each other, as is indicated by the opposed arrows 46, 46 in FIG. 6.

The greatest bending moment stresses are concentrated at the center of the'span since this is the greatest distance from the terminaledge supports and these must be transmitted in tension'laterally through the bottom skin zone means or layers and the direct tying connections thereof in the-coupling joints, as is indicated by the arrows 4'7, 47 and the double end arrows 48, 48 in FIGS. 5 and 6. It will thus be seen that composite slabs or assembly areas made up of a plurality of the modular panel units of the present invention, when coupled together by coupling joint structure thereof will effectively support vertically imposed loadswith only the terminal edges of the slab or assembly area supported on marginal support means, such as edge beams or foundation walls.

As has been previously indicated, practice of the present invention is not limited to panel units which are square orrectangular in plan, the chief requirement being that eachis a straight-sided panel so as to permit juxtaposition of. each of its straight sideedges against a straight side edge of acompanion panel unit. For example, one may substitute for one of the square modular panel units illustrated in the drawings a pair of right triangular units which may have their hypotenusal edges opposed and coupled together with a similar coupling joint, and other differently shaped straight-sided panel units may he used to practice the invention, such as those which are in plan equilateral triangular in shape or of other symmetrical polygonal planar shape.

It has also been indicated that panel units of the present invention may be executed in forms wherein the core means intervening the top and bottom planar skin zone means is structurally difierent than that proposed in FIGS. 1 to 8 incl. For example, as is indicated in FIG. 9, a modular panel unit 108 of the present invention may have its parts cast integral with each other as a unitary structure from any suitable material, such as from concrete, with the top planar skin zone means or layer 111 and bottom planar skin zone means or layer 112 integrally connected to the core, means 113: of the same composition by the castings or molding thereof. Preferably the edges of such a modular panel unit Itlfi will be shaped in the casting or molding thereof similarly to the structure illustrated in FIGS. 1 to 7 incl. so as to provide the equivalent shear strip structure 129 integral with the top skin zone means 111 and the core means 113 while providing the laterally outwardly projecting bottom edge flange 118 integral with the bottom skin zone means 112.

It has also been indicated above that the bottom skin zone means or layers may be tied together in a coupling joint structure of the present invention by means other than the butt joint illustrated in FIGS. 1 to 8 incl. Such modified tying means is illustrated by way of example in FIGS. 10 and 11. Companion panel units of the present invention 200, 290 may be similar in structure to panel units 10, 10 of the FIGS. 1 to 8 incl. embodiment except for change in the bottom planar skin layers and the means employed to tie them together in the coupling joint structure. The bottom planar skin layers 212, 212 may, for example, be made from metallic material since they are to be thickened at their opposed edges to provide lips for cooperation with keying means to tie them together. It will be understood from FIGS. 10 and 11 that the edge flange 21-8 of each bottom planar skin layer 212 is so thickened and shaped as to provide a longitudinallyextending undercut shoulder 49. The tying means is in the form of a longitudinally-extending key 50 which has a longitudinally-extending groove or channel 51, the side walls 52, 52 of which are obliquely arranged to overhang and fit complementary to the shoulders 4%, 49. Thus, when companion panel units 208 200 are aligned in edgeto-edge relation with alignment of their bottom skin layers 2-12, 212, as is indicated in FIG. 10, the tying channeled key 50 may be applied to fasten the latter together by guiding the opposed thickened portions of the flanges 213, 218' into the key groove or channel 51 and driving the key longitudinally to proper tying position. Consequently,'the

bottom planar skin layers 212, 212 are tied together continuously along their longitudinal edges. Since such channeled key tying means does not require the employment of a longitudinally-extending top batten or strap, the edge strips 1I9119 of the core means 13 may extend fully between the opposed inner faces of the top and bottom planar skin layers 11 and 212, as shown, thereby omitting the provision of the notches 24-24 employed in the FIGS. 1 to 8 incl. embodiment for reception of the side edges of each of the top straps 36.

In order to facilitate the application of the channeled tying. key 50 of the FIGS. 10 and l l embodiment the longitudinal groove or channel 51 in the key may be tapered and with like taper being provided on the shouldered thickened portions of the edge flanges 218, 218, as is indicated in FIG. 11. As a result, the thickened edge flanges 218, 218. may be readily received in the key channel 51 when the key 50 is offset laterally in a longitudinal direction a few inches from final tying position so that the greatest width of the shouldered portions of the aligned edge flanges 218, 218 in any transverse plane is less than the minimum width of the key channel in the same plane. The key 50. may then be driven home longitudinally to its locking position illustrated in FIG. 10.

Panel um'ts of the present invention are also well adapted to assembly in building constructions wherein it may be desirable to support an assembled slab of a plus rality of the units at other than the marginal edges of the slab or assembled area. For example, the supports may be located inwardly from the marginal edges of such a slab or assembled area so that marginal panel units may cantilever beyond the supports, as is illustrated in FIGS. 12 and 13. This may readily be accomplished with panel units of the present invention without material alter-ation of the structure thereof, the modified use merely requiring a simple change in the coupling joint structure.

For example, as is illustrated in FIGS. 12 and 13, companion panel units 3%, 300 may each be constructed similarly to the panel unit It} of the FIGS. 1 to 8 incl. embodiment, with each having a top planar skin layer 11, a bottom planar skin layer 12 and intervening core means 13, including vertical edge strips 19-19. The edge strips 19-19 of the core means 13 may be connected to the top and bottom skin layers 11 and 12 in similar fashion, such as by internal strips 21-41 and by shear strips 129129 which are modifications of shear strips 29--29. The laterally-projecting edge flanges 18, 18 of the bottom planar skin layers 12, 12 of the companion panel units 300, Still, which are opposed in alignment, have their side edges 53, 53 juxtaposed inabutting relation between the butt joint top strap or batten 36 and bottom strap or batten 136. The top and bottom butt straps or battens 36 and 136 are fastened to these bottom layer edge flanges 13, 18 preferably by similar means, such as drive pins mp4s. Each opposed pair of shear strips 129, 129 will likewise be provided with the longitudinallyextending opposed grooves 31, 31 to receive therein the shear key 32 in the fashion of the description of FIGS. 1 to 8 incl.

As will be seen from FIG. 13, the laterally projecting edge flanges 117, 117 of the aligned top planar skin layers 11, 11 of the companion panel units 300, 300 are to be tied together for the purpose of transmitting laterally forces in tension. For this purpose, each of the edge flanges 117 preferably will be provided with a longitudinally-extending row or series of closely spaced apertures 138-138. A longitudinally-extending tying batten or strap 236, which may be similar to the strap or batten 136, may be laid over the aligned top edge flanges 117, 117 and provided with a pair of longitudinally-extending rows or series of closely spaced holes 239239 aligned with the flanges holes 138138. Shear strips 129, 129 differ from the shear strips 29, 29 of the FIGS. 1 to 8 incl. embodiment in that each is provided with a longitudinally-extending row or series or sockets 5454 aligned with the holes 138138. T he top tying strap or batten 236 is anchored in position by a plurality of drive pins 140140 which are driven down through the aligned holes 239239 and 138138 into the sockets 54-54 so that the opposed and aligned top skin layers 11, 11 of the companion panel units 300, 300 are securely tied together for transfer therebetween of forces in tension. Since forces are to be transferred between the bottom skin layers 12, 12 in compression, it is preferred, as has been indicated, that the opposed side edges 53, 53 of the lateral- 1y extending bottom flanges 18, 18 be abutted, but it will be understood that this is not necessary since these flanges are securely tied together in the butt joint by the straps or battens 36 and 136 and pins 4040 which will efficiently efiEect lateral transfer of compressive forces therebetween.

Let it be assumed that a slab or an assembled area consisting of a plurality of panel units 30il300 are coupled together by coupling joint structure of FIG. 13 and that the span is to be supported inwardly of its terminal ends or marginal edges, such as is proposed in FIG. 12. It is therein suggested that suitable supports 15, 15 be positioned beneath coupling joint structures located inwardly of the terminal ends 55, 55 of the span a distance of one panel unit width or length. For this purpose, the butt joint straps or battens 136, 136 of these joint coupling structures may be rested upon the top ends of the supports 15, 15. If vertical load is somewhat uniformly distributed over the span so that at least some is applied to the unsupported or cantiliver free ends of the span, such as is suggested by the arrows 142, 142 in FIG. 12 and inbetween the supports 15, 15, as is suggested by the arrows 42, 42, it will be understood that the aligned bottom skin layers 12, 12 of the companion pair of panel units 301 3630 having their coupling joint structure located above one of the supports 15 will be subjected to forces in compression, such as is indicated by the arrows 146, 146. Conversely, forces will be transmitted laterally between the top skin layers 11, 11 of this companion pair of panel units 300, 308 in tension, as is indicated by the double-ended arrows 148, 148. The tying strap or batten 236 of each joint structure located over one of the supports 15 assures the eflicient transfer of such forces in tension through the top skin layers 11, 11 of this particular pair of panel units. The load may be such that the portion of the span intervening the supports 15, 15 will reverse the directions of the transfers of lateral forces in the top and bottom skin layers so that in joint structures of companion pairs of the panel units 300300 in this portion of the span forces in compression are transferred between the top skin layers 11, 11, as is indicated by the opposed arrows at 46, 46, and forces in tension will he transferred laterally between the bottom skin layers 12-12, as is indicated by the double-ended arrows 48, 48, just -as in the FIG. 6 illustrated use of the embodiment of FIGS. 1 to 8 incl. If the nature of the vertical load to be imposed on such a span is predetermined so that it is known that forces in compression are transferred between the top skin layers 1111 and forces in tension are transferred between the bottom skin layers 12-12 at the coupling joints of the aligned panel units 300300 in the span portion intervening the supports 15, 15, it will not be necessary to employ the top tying straps or battens 236236 in the coupling joint structures which intervene these supports, but the need for such determination may be avoided if such top tying straps or battens are mounted when the panel units are connected together in the cantilever span. It is a simple matter to avoid interference with free travel over such a span by the presence of such top tying straps or battens 236-236 when a plurality of such panel units 390-600 are assembled together in floor spans or slabs, such as by overlaying the structure with suitable sheathing material or floor covering or by filling in between the top tying straps or battens.

It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Having described my invention, What I claim as new and desire to secure by Letters Patent is:

1. Companion building panels designed for use as floor, roof and the like subassembly units comprising, in combination, a plurality of straight-sided panels joined in tandem, one to the next, to form a structurally continuous beam supported primarily at the extreme ends thereof, each panel having opposite transverse end edges with one of the latter of one of an adjacent pair of said pane-ls abutted and joined to one of said end edges of the next of said pair in a disconnectable coupling joint, each panel including vertically-spaced top and bottom planar skin zone means and intervening core means permanently connected together, the top skin zone means of each of said adjacent pair of panels having a lateral edge opposed to and substantially aligned with the lateral edge of the same top skin zone means of the adjacent one of said paired panels in said disconnectable coupling joint with these opposed zone means edges being arranged in lateral compressive stress transfer relation relative to each other, means in said coupling joint impermanently interlocking the transverse end edge of one of said pair of panels directly to the other thereof against relative vertical motion in shear, said interlocking means being demountable with respect to at least one of said end edges by lateral separation of the opposed end edges to permit disconnection of said paired panels, the bottom skin zone means of each of said paired panels having a lateral edge opposed to and substantially aligned with the lateral edge of the same bottom skin zone means of the adjacent one of said paired panels in said joint, and separate elongated disconnectable connecting means extending longitudinally along and adjacent to the opposed bottom skin zone means edges of said paired panels and disconnectably connecting said latter opposed edges directly to each other at at least a large number of closely spaced points impermanently tying them directly together for direct lateral trans fer therebetween of bending moment stress in tension.

2. Companion building panels designed for use as floor, roof and the like subassembly units comprising, in combination, a plurality of straight-sided polygonal flat panels joined in tandem, one to the next, to form a structurally continuous beam supported primarily at the extreme ends thereof, each panel having opposite transverse end edges with one of the latter of one of an adjacent pair of said panels abutted and joined to one of said end edges of the next of said pair in a disconnectable coupling joint, each panel including vertically-spaced top and bottom planar skin zone means and intervening core means permanently connected together with a straight side edge of one of said adjacent pair of panels being opposed to that of the other of said pair in said disconnectable coupling joint, an edge of the top skin zone means of each of said paired panels being substantially aligned with and arranged relative to that of the adjacent one of said paired panels for lateral compressive stress transfer therebetween, interlocking means in said coupling joint impermanently holding the side edge of one of said paired panels directly to that of the other of said paired panels against relative vertical motion in shear, said interlocking means being demountable with respect to at least one of said side edges by lateral separation of the Opposed side edges to permit disconnection of said paired panels, the bottom skin zone means of each of said paired panels having a lateral projecting edge opposed to and substantially aligned with that of the adjacent one of said paired panels in said joint, and continuous separate elongated disconnectable connecting means extending longitudinally and adjacent to the opposed bottom skin zone means edges of said paired panels and disconnectably connecting said latter opposed edges directly to each other at at least a large number of a plurality of closely spaced points throughout the extent of these edges for direct lateral transfer therebetween of bending moment stress in tension.

3. The structure as defined in claim 2 characterized by the opposed side edges of said paired panels being provided in said joint with said interlocking means in the form of opposed elongated elements fixed in the edge structures of said paired panels and having opposed grooves, and elongated locking spline means seated in the opposed grooves.

4. The structure as defined in claim 3 characterized by said direct connection. of said bottom skin zone means being in the form of a butt joint having the continuous elongated connecting means in the form of at least one tying batten lapped against and removably fastened at the closely spaced points to both of the opposed edges of said bottom skin zone means of said paired panels.

5. The structure as defined in claim 4 characterized by said connecting means being in the form of a pair of elongated battens lapped to opposite side faces of the opposed bottom skin zone means edges, and removable pin means fastening'said battens to said opposed edges at the closely spaced points.

6. Companion building panels designed for use as floor, roof and the like subassembly units comprising, in combination; a plurality of interchangeable rectangular flat'panels each having four like side edges, verticallyspaced top and bottom planar skin layers and intervening core means all permanently connected together, a side edge of one of an adjacent pair of panels being opposed to and removably fastened to one side edge of the other of said paired panels in a panel side edge coupling joint, an edge of oneof the topand botom skin layers of each of said paired panels being substantially aligned with and abutted'to an edge of the same skin layer of the adjacent one of said paired panels for lateral compressive stress transfer therebetween; interlocking means in said joint comprising opposed elongated elements each structurally fixed into and extending along one of the opposed panel side edges with each having a longitudinal groove in its opposing face and with the grooves longitudinally aligned and opposed to each other, and an elongated spline member removably seated in at least one of said opposed grooves; the other of the top and botom skin layer of each of said paired panels having a lateral projecting edge flange opposed to and substantially aligned with a similar lateral projecting edge flange of the same skin layer of the adjacent one of said paired panels in said joint with each of said second-mentioned layer edge flanges provided with. a longitudinally-extending series of closely spaced vertical holes; an elongated batten juxtaposed to faces of said second-mentioned aligned layer edge flanges and lapping against the latter, said batten having a pair of transversely-spaced, longitudinally-extending series of vertical 'holes with those of one series aligned with the holes in one of said edge flanges and those of the other series aligned with the holes in the other of said edge flanges; and removable drive pins extending through the aligned holes in said batten and edge flanges thereby directly connecting the latter together in a butt joint for direct lateral transfer between said bottom skin layers of bending moment stress in tension.

72 Companion building panels designed for useas floor,

roof and the like subassenrbly units comprising, in companels. each having four like side edges, vertically-spaced top and'bottom planar skin layers and intervening core means all permanently connected together, a side edge of one of an adjacent pair of panels being opposed to and removably fastened to one side edge of the other of said. paired panels in a panel side edge coupling joint, an edge of the top skin layer of each of said paired panels being substantially aligned with and abutted to that of the adjacent one of said paired panels for lateral compressive stress transfer therebetween; interlocking means in said joint comprising opposed elongated elements each structurally fixed into and extending along one of the opposed panel side edges witheach having a longitudinal groove in its opposing face and with the grooves longitudinally aligned and opposed to each other, and an elongated spline member removably seated in said opposed grooves; the bottom skin layer of each of said paired panels having a lateral projecting edge flange opposed to and substantially aligned with that of the adjacent one of said paired panels in said joint with each of said bottom layer edge flanges provided with a longitudinallyextending series of closely spaced vertical holes; a pair of elongated battens juxtaposed to oposite faces of said bottom layer edge flanges and lapping against the latter, each of said battens having a pair of transversely-spaced, longitudinally-extending series of vertical holes with those of one series aligned with the holes in one of said edge flanges and those of the other series aligned with the holes in the other of said edge flanges; and removable drive pins extending through the aligned holes in said battens and edge flanges thereby directly connecting the latter together in a butt joint for direct lateral transfer between said bottom skinlayers of bending moment stress in tension.

8. The structure as defined in claim 7 characterized by said aligned top skin layers of said paired panels having lateral projecting flanges carrying said opposed and abutted top edges with said interlocking grooved elements being located adjacent the inside faces of these top layer edge flanges and spaced appreciably above said bottom layers butt joint with the structure of said opposed panel side edges in said coupling joint between said top. and bottom edge flanges being appreciably spaced transversely, thereby defining in said coupling joint a longitudinallyextending channel.

9. A modular building panel designed for use as a floor, roof and the like subassembly unit comprising, in combination, a rectangular panel having four like side edges and vertically-spaced planar top and bottom skin layers, rectangular core means mounted between said layers and having four substantially vertical outside edges interposed between said top and bottom skin layers with edge zones of the latter extending laterally outward beyond said core outside edges in overhanging relation defining paired top and bottom lateral edge flanges on all four sides with provision of a set of the top edge flanges and another set of the botom edge flanges, four shear strips each fixedly mounted in the angle between one of the outside faces of said core means and the top edge flange overhanging the latter with each sear strip having a substantially vertical outside edge face provided with a. longitudinally-extending groove for reception of shear spline means with each shear strip being spaced appreciably above the bottom edge flange located therebelow, all of these parts being permanently connected together, each of said set of top edge flanges being alignable with a like top edge flange of an adjacent like modular panel in a coupling joint and associated therewith in lateral stress transfer relation, each of said set of bottom edge flanges being alignable with the like bottom edge flange of an adjacent like modular panel in such coupling joint and associated therewith in lateral stress transfer relation, and at least one of the sets of the top and bottom edge flanges being provided with means for directly and disconnectably connecting them in coupling joints to like edge flanges of adjacent like modular panels, said connecting means including structure defining a longitudinally-extending series of closely spaced pin-receptive vertical holes in each of said edge flanges of said set.

10. A modular building panel designed for use as a floor, roof and the like subassembly unit comprising, in combination, a rectangular panel having four like side edges and vertically-spaced planar top and bottom skin layers, rectangular core means mounted between said layers and having four substantially vertical outside edges interposed between said top and bottom skin layers with edge zones of the latter extending laterally outward beyond said core outside edges in overhanging relation to define paired .top and bottom lateral edge flanges on all four sides, four shear strips each fixedly mounted in the angle between one of the outside faces of said core means and the top edge flange overhanging the latter with each shear strip having a substantially vertical outside edge face provided with a longitudinally-extending groove for reception of shear spline means, all of these parts being permanently connected together, each shear strip being spaced appreciably above the bottom edge flange located therebelow with its grooved outside face extending laterally outward no farther than the edge of said top edge flange whereby a pair of the latter of an adjacent pair of the modular panels may be abutted in a coupling joint for lateral compressive stress transfer therebetween, and means for directly and disconnectably connecting in a coupling joint each of said bottom edge flanges to an aligned one of an adjacent like modular panel with said means defining a longitudinally-extending series of closely spaced pin-receptive vertical holes.

11. A modular building panel designed for use as a floor, roof and the like subassembly unit comprising, in combination, a rectangular panel having four like side edges and vertically-spaced planar top and bottom skin layers, rectangular core means mounted between said layers and having four substantially vertical outside edges interposed between said top and bottom skin layers with edge zones of the latter extending laterally outward be yond said core outside edges in overhanging relation to define paired top and bottom lateral edge flanges on all four sides, four shear strips each fixedly mounted in the angle between one of the outside faces of said core means and the top edge flange overhanging the latter with each shear strip having a substantially vertical outside edge face provided with a longitudinally-extending groove for reception of shear spline means, all of these parts being permanently connected together, each shear strip being spaced appreciably above the bottom edge flange located therebelow with its grooved outside face extending laterally outward no farther than the edge of said top edge flange whereby a pair of the latter of an adjacent pair of the modular panels may be abutted in a coupling joint for lateral compressive stress transfer therebetween,

means for directly and disconnectably connecting in a coupling joint each of said top edge flanges to an aligned one of an adjacent like modular panel with said means defining a longitudinally-extending series of closely spaced pin-receptive vertical holes extending through said top edge flange and into the shear strip located therebelow, and means for directly and disconnectably connecting in a coupling joint each of said bottom edge flanges to an aligned one of an adjacent like modular panel with said means defining a longitudinally-extending series of closely spaced pin-receptive vertical holes extending through said bottom edge flange.

12. In a building construction a laterally-extending floor or roof structure comprising in combination, a pair of laterally-separated end supports for imposition of vertical loads thereon and a structurally continuous longitudinal beam supported primarily at its extreme ends on said supports, said beam comprising a plurality of straightsided companion panels joined in tandem, one to the next, with each panel having opposite transverse ends and with one of said ends of one panel of an adjacent pair thereof abutted and joined to one of said ends of the next of said pair of panels in a coupling joint, each panel including vertically-spaced top and bottom planar skin zone means and intervening core means permanently connected together as a unit, the top skin zone means of each of said pair of panels having a lateral edge opposed to and substantially aligned with the lateral edge of the same top skin zone means of the adjacent one of said paired panels in said coupling joint with these opposed zone means edges being arranged in lateral compressive stress transfer relation relative to each other, means in said coupling joint interlocking the transverse end edge of one of said pair of panels directly to the other thereof against relative vertical motion in shear, the bottom skin zone means of each of said paired panels having a lateral edge opposed to and substantially aligned with the lateral edge of the same bottom skin zone means of the adjacent one of said paired panels in said joint, and separate elongated connecting means extending longitudinally along and adjacent to the opposed bottom skin zone means edges of said paired panels and connecting said latter opposed edges at at least a large number of closely spaced points tying them directly together for direct lateral transfer therebetween of bending moment stress in tension.

References Cited in the file of this patent UNITED STATES PATENTS 818,884 Grimm Apr. 24, 1906 1,214,442 Edlin Ian. 30, 1917 1,337,745 Bassett Apr. 20, 1920 2,008,557 Lambert July 16, 1935 2,053,135 Dalton Sept. 1, 1936 2,220,690 Stupakoif Nov. 5, 1940 2,394,146 Brunton Feb. 5, 1946 

1. COMPANION BUILDING PANELS DESIGNED FOR USE AS FLOOR, ROOF AND THE LIKE SUBASSEMBLY UNITS COMPRISING, IN COMBINATION, A PLURALITY OF STRAIGHT-SIDED PANELS JOINED IN TANDEM, ONE TO THE NEXT, TO FORM A STRUCTURALLY CONTINUOUS BEAM SUPPORTED PRIMARILY AT THE EXTREME ENDS THEREOF, EACH PANEL HAVING OPPOSITE TRANSVERSE END EDGES WITH ONE OF THE LATTER OF ONE OF AN ADJACENT PAIR OF SAID PANELS ABUTTED AND JOINED TO ONE OF SAID END EDGES OF THE NEXT OF SAID PAIR IN A DISCONNECTABLE COUPLING JOINT, EACH PANEL INCLUDING VERTICALLY-SPACED TOP AND BOTTOM PLANAR SKIN ZONE MEANS AND INTERVENING CORE MEANS PERMANENTLY CONNECTED TOGETHER, THE TOP SKIN ZONE MEANS OF EACH OF SAID ADJACENT PAIR OF PANELS HAVING A LATERAL EDGE OPPOSED TO AND SUBSTANTIALLY ALIGNED WITH THE LATERAL EDGE OF THE SAME TOP SKIN ZONE MEANS OF THE ADJACENT ONE OF SAID PAIRED PANELS IN SAID DISCONNECTABLE COUPLING JOINT WITH THESE OPPOSED ZONE MEANS EDGES BEING ARRANGED IN LATERAL COMPRESSIVE STRESS TRANSFER RELATION RELATIVE TO EACH OTHER, MEANS IN SAID COUPLING JOINT IMPERMANENTLY INTERLOCKING THE TRANSVERSE END EDGE OF ONE OF SAID PAIR OF PANELS DIRECTLY TO THE OTHER THEREOF AGAINST RELATIVE VERTICAL MOTION IN SHEAR, SAID INTERLOCKING MEANS BEING DEMOUNTABLE WITH RESPECT TO AT LEAST ONE OF SAID END EDGES BY LATERAL SEPARATION OF THE OPPOSED END EDGES TO PERMIT DISCONNECTION OF SAID PAIRED PANELS, THE BOTTOM SKIN ZONE MEANS OF EACH OF SAID PAIRED PANELS HAVING A LATERAL EDGE OPPOSED TO AND SUBSTANTIALLY ALIGNED WITH THE LATERAL EDGE OF THE SAME BOTTOM SKIN ZONE MEANS OF THE ADJACENT ONE OF SAID PAIRED PANELS IN SAID JOINT, AND SEPARATE ELONGATED DISCONNECTABLE CONNECTING MEANS EXTENDING LONGITUDINALLY ALONG AND ADJACENT TO THE OPPOSED BOTTOM SKIN ZONE MEANS EDGES OF SAID PAIRED PANELS AND DISCONNECTABLY CONNECTING SAID LATTER OPPOSED EDGES DIRECTLY TO EACH OTHER AT AT LEAST A LARGE NUMBER OF CLOSELY SPACED POINTS IMPERMANENTLY TYING THEM DIRECTLY TOGETHER FOR DIRECT LATERAL TRANSFER THEREBETWEEN OF BENDING MOMENT STRESS IN TENSION. 